cashco 1000HP Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL IOM-1000HP-
Differential
01-17
MODEL 1000HP - DIFFERENTIAL
PRESSURE REDUCING REGULATOR
SECTION I
I. DESCRIPTION AND SCOPE
The Model 1000HP-1+6 and 1000HP-1+8 are differential pressure reducing regulators used to control differential
pressure between downstream (outlet or P2) pressure and a loading (PLoad) pressure to the spring chamber. Sizes
are 1/2" , 3/4", 1", 1-1/4", 1-1/2" and 2" (DN15, 20, 25, 32, 40 and 50). With proper trim utilization and jet selection,
this unit is suitable for liquid, gaseous, or steam service. Refer to Technical Bulletin 1000HP-DIFF-TB for sizing,
application and selection recommendations.
SECTION II
II. INSTALLATION
1. An inlet block valve should always be installed.
An outlet block valve is desirable.
2. A manual bypass valve is recommended for “hot
piping” systems to assist in piping warm-up at
startup.
3. An isolation valve on the loading line is not
recommended. The annular body ring of the
1000HP-1+8 may be piped to a safe drainage
point, but no valve should be installed in the drain
line.
4. Pipe unions must be installed to allow removal from
piping. Trim can only be changed by unit removal
from pipeline. If flanges are utilized, a lap joint
flange is required on the inlet end of the regulator
to help align bolt holes as the cylinder screws into
place. NOTE: Cashco does not recommend field
welding on the cylinder (inlet) end of the valve due
to the possibility of warpage.
CAUTION
Recommended Piping Schematic for
Differential Pressure Reducing Station
DO NOT HYDROSTATIC TEST THROUGH AN
INSTALLED UNIT; ISOLATE FROM TEST. DO NOT
HYDROSTATIC TEST THE LOADING PRESSURE
WITHOUT PRESSURE IN THE MAIN REGULATOR.
The nameplate indicated outlet pressure rating, if
reached, may cause internal damage. Refer to Technical
Bulletin Model 1000HP-DIFF-TB, Table 3 for “emergency
overpressure level” that will not do irreparable internals
damage. In addition, note on the nameplate that the
Inlet and Outlet pressure and temperature ratings are
at different levels.
5. An outlet pressure gauge should be located
approximately ten pipe diameters downstream,
and within sight. A loading pressure (or differential
pressure) gauge is recommended.
6. All installations should include a downstream
relief device if the inlet pressure could exceed the
pressure rating of any downstream equipment or
the maximum outlet pressure rating of the unit.
7. Clean the piping of all foreign material including
chips, welding scale, oil, grease and dirt
before installing the regulator. Strainers are
recommended.
8. In placing thread sealant on pipe ends prior to
engagement, ensure that excess material is
removed and not allowed to enter the regulator
upon startup.
9. Flow Direction: Install so the flow direction matches
the arrow cast on the body.
ISO Registered Company

2IOM-1000HP-Differential
∆PSizing = P1- P2
P2> PLoad
P2= PLoad + PSet
∆PDifferential = P2- PLoad
diaphragm design): Regulator may be rotated
around the pipe axis 360° and may be installed
in a horizontal or vertical pipeline.
12. Regulators are not to be direct buried underground.
10. For best performance, install in well drained
horizontal pipe, properly trapped if a steam service
application.
11. Differential Regulator – (Refer to Dwg. Opt-1+6
for single diaphragm or Dwg. Opt-1+8 for double
SECTION III
III. PRINCIPLE OF OPERATION
1. The differential Model 1000HP is also available
in two options: 1000HP-1+6 is single diaphragm
construction; 1000HP-1+8 is double diaphragm
construction. The double diaphragm construction
prevents the loading fluid from direct mixing with
the system fluid in case of diaphragm failure.
2. Movement occurs as pressure variations register
on the diaphragm. One pressure is the outlet (p2)
or downstream pressure, which registers on the
“underneath” side of the diaphragm. The second
pressure registered is the loading (PLoad) pressure
in the spring chamber “above” the diaphragm.
The range spring determines the differential
pressure level (PSet). As outlet (P2) pressure
drops, the range spring pushes the diaphragm
down, opening the port; as outlet (P2) pressure
increases, the diaphragm pushes up and the port
closes. As the loading (PLoad) pressure varies, the
outlet (P2) pressure tends to follow. An increase
in PLoad (∆PLoad) will increase outlet P2pressure
by nearly an equal amount (∆PLoad = ∆P2); a
decrease in PLoad will have a similar effect on
outlet P2pressure.
3. The Model 1000 includes a rocker arm in its
operation mechanism. The rocker arm allows the
regulator to operate flow-to-open (FTO), rather
than conventional flow-to-close (FTC), which
increases rangeability.
4. Due to the FTO design, there is a limit as to how
low of a downstream (P2or outlet) pressure level
setting is capable for a given inlet P1pressure.
This is a function of the ratio of the port area to the
diaphragm area. It is possible for there to be too
high of an inlet pressure for the regulator to close
off against. (Refer to 1000HP-DIFF-TB, Tables 9,
10, 11 and 12 for limits.) Reduced port, Opt-12,
allows lower downstream (P2or outlet) pressure
settings for a given upstream (P1or inlet) pressure
level.
5. The Model 1000 includes an aspiration jet effect,
due to the clearance of the piston from the body
near the outlet. These clearances vary as to
whether the fluid is a gas (including steam), a liquid,
or a viscous liquid (required Opt-27). Jets must
be selected to match one of these three general
fluids. An improper jet will reduce performance.
NOTE: The regulator requires minimum output
pressure level or the regulator will not close.
LOADING
FLUID @ PLoad
RANGE SPRING:
SETTING @ PSet
Diaphragm
OUTLET
@ P2
& T2
1000HP-1+6
DIFFERENTIAL SCHEMATIC
6. For a 1000HP-1+6 (single diaphragm) design, a
complete diaphragm failure will cause the fluids
to mix in the spring chamber or loading pressure
piping system.
7. For a 1000HP-1+8 (double diaphragm) design, a
complete diaphragm failure will cause the regulator
to fail open, leaking fluid through the annular ring
vent hole.
NOTE: Composition (soft) diaphragms may be
utilized only on -1+6 single diaphragm construction.
8. For viscous fluids normally heated (heavy fuel
oil), it may be desirable to include a flow-through
spring chamber, the -65 Option.

3IOM-1000HP-Differential
IV. STARTUP
1. Start with the block valves closed. A bypass valve
may be used to maintain outlet pressure in the
downstream system without changing the following
steps.
2. Remove closing cap and relax the range spring
by turning the adjusting screw counterclockwise
(CCW) a minimum of three (3) full revolutions.
This reduces the outlet (downstream) pressure
set point.
3. If it is a “hot” piping system, and equipped with
a bypass valve, slowly open the bypass valve
to pre-heat the system piping and to allow slow
expansion of the piping. Ensure proper steam
trap operation if installed. Closely monitor outlet
(downstream) pressure, via gauge, to ensure not
over-pressurizing. NOTE: If no bypass valve is
installed, extra caution should be used in starting
up a cold system; i.e. do everything slowly.
Do not walk away and leave a bypassed regulator
unattended!
4. Crack open the outlet (downstream) block valve.
5. Slowly open the inlet (upstream) block valve
observing the outlet (downstream) pressure gauge.
Determine if the regulator is flowing. If not, slowly
rotate the regulator adjusting screw clockwise
(CW) until flow begins.
6. Continue to slowly open the inlet (upstream) block
valve until fully open.
7. Continue to slowly open the outlet (downstream)
block valve, especially when the downstream
piping system isn’t pressurized. If the outlet
(downstream) pressure exceeds the desired
pressure, close the block valve and go to Step 2,
then return to Step 4.
8. When flow is established steady enough that the
outlet (downstream) block valve is fully open, begin
to slowly close the bypass valve if installed.
9. Set the regulator set point (Pset) by turning the
adjusting screw clockwise (CW) to increase outlet
pressure or CCW to reduce outlet pressure. The
outlet (P2) pressure under these conditions will
approximate the desired differential pressure when
loaded with PLoad.
10. Pressurize the source of loading (PLoad) pressure
and allow to fill the spring chamber cavity. Slightly
open the bleeder valve to vent any air as the spring
chamber is filling.
11. Develop system flow and pressure and readjust
setpoint as required to obtain desired response.
Performance should be analyzed at minimum and
maximum flow levels.
12. Install closing cap.
SECTION V
CAUTION
Loading Pressure must be shut off before shutting
down the system pressure.
1. To prevent force imbalances and possible
diaphragm failure, the loading pressure (PLoad)
should always be shutdown first from its source of
pressure. Systems sequencing must ensure this
occurs.
CAUTION
2. It is recommended that manual operation not be
attempted by a bypass valve during a shutdown.
3. When the loading pressure (PLoad) has been
shutdown, the regulator outlet pressure (P2) should
decrease substantially. When this is observed, the
inlet (upstream) block valve may be closed.
V. SHUTDOWN
SECTION IV

4IOM-1000HP-Differential
SECTION VI
WARNING
(19) is not used with a composition (soft)
diaphragm.)
NOTE: The text hereafter will refer to:
a. The -1+8 double diaphragm optional
construction (-1+6 single diaphragm
construction is similar. Text regarding
composition diaphragm(s) (20)
applies only to -1+6 option). Text
portions dealing with body spacer (42),
diaphragm spacer (41) and separation
of total diaphragm (20) quantity into two
“stacks” applies only to -1+8 option.
b. The “pusher plate and stud” (13) as a
single part for 1/2" – 1-1/4" sizes and
as two separate parts, a “pusher plate”
(5) and a “pusher stud” (13) , for 1-1/2"
and 2" sizes.
7. Pry up the diaphragm(s) (20) and diaphragm
gasket (19) around the perimeter of the body (1)
diaphragm flange to ensure the diaphragm(s)
(20) are not “sticking”. (Diaphragm gasket
(19) is not used with a composition (soft)
diaphragm.)
WARNING
2. Remove closing cap (31). Relax range spring
(27) by turning adjusting screw (6) CCW until
removed from spring chamber (2).
3. Paint or embed a match mark between body
casting (1), spring chamber casting (2), and
body spacer (42) along flanged area.
4. Remove all diaphragm flange nuts (9) and
bolts (8). Remove nameplate (28).
5. Remove spring chamber (2), spring button (4)
and range spring (27).
6. Pry up the diaphragm(s) (20) and diaphragm
gasket (19) around the perimeter of the spring
chamber (2) flange to ensure the diaphragm(s)
(20) are not “sticking”. (Diaphragm gasket
VI. MAINTENANCE
SYSTEM UNDER PRESSURE. Prior to performing
any maintenance, isolate the regulator from the
system and relieve all pressure. Failure to do so
could result in personal injury.
A. General:
1. Maintenance procedureshereinafter arebased
upon removal of the unit from the pipeline
where installed.
2. Owner should refer to owner’s procedures for
removal, handling and cleaning of reusable
parts, and disposal of non-reusable parts, i.e.
gaskets.
3. If desired, the gaskets may be lubricated with
a light oil provided it is compatible with the
fluid.
B. Diaphragm Replacement:
1. Securely install the body (1) in a vice with the
spring chamber (2) directed upwards.
SPRING UNDER COMPRESSION. Prior to
removingflangebolts,relievespringcompression
by backing out the adjusting screw. Failure to
do so may result in flying parts that could cause
personal injury.
8. Remove diaphragm subassembly by sliding
the pusher plate and stud (13), body spacer
(42) and nut (11) in the direction of the regulator
inlet, approximately 1/2"–3/4" (15-20 mm)
The pusher plate and stud (13), stud nut
(10), and stud collar (16) should disengage
with the rocker arm (14) slot. Lift vertically for
diaphragm subassembly removal, carefully
holding the assembly at its outer edge to
prevent the body spacer (42) from falling from
between the diaphragm(s) (20).

5IOM-1000HP-Differential
9. Place the pusher plate stud (13) in a separate
vise, gripping the stud (13) on the hexagonal
cast-in-place edges located on the underneath
side of the pusher plate stud. NOTE: Do not
remove the stud nut (10), stud collar (16), and
the location locking cotter pin (15).
10. Loosen and remove nut (11).
11. Lift and remove pressure plate (3) and O-ring
(50).
12. Remove upper diaphragm(s) (20), diaphragm
spacer (41) and body spacer (42).
13. Pry loose pusher plate and stud (13) from lower
diaphragm(s) (20) or from lower pusher plate
gasket (12). (Pusher plate gasket (12) is not
utilized with composition (soft) diaphragm.)
Remove the diaphragm(s) (20).
14. Remove pusher plate gasket (12) from pusher
plate and stud (13).
15. Clean gasket sealing surfaces of pusher plate
and stud (13), spring chamber (2), body (1),
and pressure plate (3) thoroughly.
16. Install new pusher plate gasket (12) over
pusher plate and stud (13).
17. Install one-half of total quantity of new
diaphragm(s) (20) over pusher plate and stud
(13). NOTE: Refer to quantity of diaphragms
(20) incorporated in the bill of materials
listing. Depending on outlet pressure level,
various quantities of metal diaphragms will be
“stacked”. They should always be in multiples
of two for -1+8 option.
18. Place diaphragm spacer (41) over pusher
plate and stud. Place body spacer (42) over
outer perimeter of diaphragm(s) (20).
19. Install remaining quantity of diaphragm(s) (20)
over pusher plate and stud (13).
20. Place O-ring (50) over pusher plate and stud
(13).
21. Inspect pressure plate (3) to ensure no
deformation due to over-pressurization.
If deformed, bent, or otherwise distorted,
replace.
22. Ensuring that the curved outer rim side of the
pressure plate (3) is down, place the pressure
CAUTION
Do not use your fingers to hold diaphragms (20)
during tightening of nut (11)!
23. Remove cotter pin (15) securing stud nut (10)
to lower end of pusher plate and stud (13),
and replace with a new pin (15). (Do not allow
the stud nut (10) to move when the cotter pin
(15) is removed.)
24. Remove rocker arm shaft (17) and rocker
arm (14). Measure inside of rocker arm (14)
“prongs” as indicated in the following diagram.
If either of the below dimensions are exceeded
by 1/8" (3mm), replace rocker arm (14).
plate (3) over the pusher plate and stud (13).
Place nut (11) onto the stud (13) and tighten.
Recommended torques are as follows:
Use two flange bolts (8) to keep multiple
diaphragms’ (20) bolt holes properly aligned
while tightening the nut (11).
Body Size Metal Diaphragm Comp. Diaphragm
3/8" – 1/2" 45–50 ft. lbs. 25–30 ft. lbs.
3/4" – 1" 45–50 ft. lbs. 30–45 ft. lbs.
1-1/4" – 2" 80–90 ft. lbs. 50–60 ft. lbs.
Valve Size
DIM MAT'L 1/2" (DN15) 3/4" (DN20) 1" (DN25)
A BRZ 7/8" 22 mm 1-5/32" 29 mm 1-7/16" 37 mm
B BRZ 5/8" 16 mm 25/32" 20 mm 3/4" 20 mm
A SST 13/16" 21 mm 1-1/16" 27 mm 1-7/16" 37 mm
B SST 9/16" 14 mm 23/32" 18 mm 3/4" 20 mm
DIM MAT'L 1-1/4" (DN32) 1-1/2" (DN40) 2" (DN 50)
A BRZ 1-13/16" 46 mm 1-25/32" 45 mm 2-3/16" 56 mm
B BRZ 29/32" 23 mm 7/8" 22 mm 29/32" 23 mm
A SST 1-1/2" 38 mm 1-25/32" 45 mm 2-5/32' 55 mm
B SST 11/16" 17 mm 7/8" 22 mm 29/32" 23 mm

6IOM-1000HP-Differential
25. Check rocker arm shaft (17) for wear and
straightness. Replace if damaged. Reinstall
in body (1) through rocker arm (14). Apply
thread sealant to the rocker arm shaft (17)
threads prior to tightening. Make sure that the
rocker arm shaft (17) enters the support slot
opposite the threaded opening, and does not
align crooked and restrained from full thread
engagement of the rocker arm shaft (17).
Make sure that the rocker arm (14) prongs
that straddle the piston (24) hold the piston
collar (23) against the piston (24); do not allow
the rocker arm (14) prongs to push directly on
the piston (24).
26. Install a new diaphragm gasket (19).
Composition (soft) diaphragms require no
diaphragm gasket. NOTE: Use only gaskets
manufactured by Cashco, Inc., that are of the
same material as those originally supplied.
Substitution may cause improper gasket
compression. It may also adversely change
the diaphragm setting, which will affect the
unit’s performance, i.e. Option 1000-45, non-
asbestos construction utilizes special gaskets.
27. Using small gauge wire approximately 18"
(457 mm) long, form a hook and place the
hook over one prong of the rocker arm (14),
and rotate the rocker arm (14) up until slack
is removed in the mechanism. Secure the
wire through a body (1) flange bolt hole on
the outlet side of the regulator.
28. Firmly holding the outer perimeter, take the
diaphragm subassembly (Step 8) and lower
it down into the body (1) cavity off-center
approximately 3/4"–1" (20–25 mm) and
towards the inlet side of the regulator. When
fully lowered,slide thediaphragm subassembly
horizontally towards the regulator outlet. The
wire of Step 27. should hold the rocker (14) up
to allow engaging of the pusher plate and stud
(13) (with stud nut (10) and stud collar (16)),
so the rocker arm (14) prongs rest directly
on the stud collar. NOTE: DO NOT ALLOW
THE ROCKER ARM (14) PRONGS TO GET
BETWEEN THE STUD NUT (10) AND THE
STUD COLLAR (16). Pull firmly to remove
wire holding rocker arm (14) up.
29. Align diaphragm(s) (20) bolt holes with body (1)
flange bolt holes. Install new diaphragm gasket
(19) on top of diaphragm(s) (20). Visually
center range spring (27) on to pressure plate
(3), place spring button (4) on top of range
spring (27).
30. Aligning the matchmarks, place spring
chamber (2) over the above stacked parts.
Install all bolts (8), nuts (9) and nameplate (28)
by hand tightening. Tighten bolting (8 and 9)
in a cross pattern that allows spring chamber
(2) to be pulled down evenly. Recommended
torques are as follows.
Body Size Bolt Size Metal Diaph 1Comp Diaph 2
1/2" 3/8"-24 25 ft-lb 25 ft-lb
3/4" 7/16"-20 30 ft-lb 30 ft-lb
1"–1-1/4" 1/2"-20 35 ft-lb 35 ft-lb
1-1/2" 9/16"-18 45 ft-lb 45 ft-lb
2" 5/8"-18 45 ft-lb 45 ft-lb
1Minimum recommended torque regardless of gasket
materials. Some gasket materials may require higher
bolt torques to obtain adequate seal.
2Gasket material may “set” with time; a recheck of
torques should be made if the unit has been stored
on the shelf for over 30 days.
NOTE: Never replace bolting (8 and 9) with just
any bolting. Bolt heads and nuts are marked
with specification identification markings. Use
only proper grades as replacements.
31. Reinstall adjusting screw (6) with sealing
locknut (7); install new closing cap gasket
(32); install closing cap (31).
32. Pressurizing the body (1) and spring chamber
(2) to the same level, soap solution test around
bolting (8 and 9), body (1), spring chamber
(2) flanges, closing cap (31) and cylinder
(21) - to body (1) joint for leakage. Use 100
psig minimum inlet pressure to leak test.
Actual service conditions should be used if
in excess of the minimum condition. (NOTE:
Do not pressurize spring chamber without
equal or greater pressure in body registering
on diaphragm(s) (20) underneath side.)
C. Diaphragm Setting Adjustment:
1. In the previous “Sub-Section B., Diaphragm
Replacement”, care was taken to prevent
removal of the stud collar (16) and stud nut
(10). Location of the stud nut (10) is a critical
adjustment for a Model 1000 regulator.
2. Not removing the stud nut (10) will provide
performance equal to original factory
performance when diaphragm(s) (20)
is replaced with like diaphragm(s) (20);
however, if the stud nut (10) is removed, or
a switch is made from metal to composition
(soft) diaphragm(s) (20), or vice versa, the
diaphragm setting should be checked.

7IOM-1000HP-Differential
3. Follow procedure “Sub-Section B., Diaphragm
Replacement” to the point of removing
diaphragm(s) (20), Step 13. Remove
diaphragm gasket (19) and pusher plate stud
gasket (12). Obtain a flat 12" x 1-1/2" x 1/4"
(15 mm x 40 mm x 6 mm) plate bar with a
3/4" (20 mm) hole drilled in the center. “Hook”
the pusher plate stud (13) into the rocker arm
(14) prongs properly. Pull firmly up on the
pusher plate stud (13) to ensure that all slack
is removed from the mechanism and that the
piston (24) is seated firmly. Relax the pulling
and place the flat bar over the pusher plate
stud (13) with the stud (13) passing through the
hole of the bar. Again, pull firmly up to remove
mechanism slack. One of three positions will
be reached:
a. Diaphragm setting too high. Pusher plate
stud (13) will lift the flat bar over 0.020"
(.51 mm).
b. Diaphragm setting acceptable. Bar lifted
between 0.010"–0.020" (.25–.51 mm).
c. Diaphragm setting too low. Bar lifted less
than 0.010" (.25 mm), or failed to be lifted.
4. The castle style stud nut (10) has six locations
per revolution to align the stud nut (10) slots
with the drilled hole through the pusher plate
stud (13). Each stud nut (10) slot represents
a movement up/down of 0.010" (.25 mm).
NOTE: The ideal diaphragm setting is 0.015"
(.4 mm) high. Better performance is usually
obtained when the diaphragm is at this value,
rather than a lower level. As the measuring of
a thousandths of an inch is difficult with such
a procedure, it is recommended that the “null”
position be found where the diaphragm(s)
(20) is flush with the body (1) flange (bar
approximately at 0.000"). Remove the pusher
plate stud (13), rotate the stud nut (10) one
or two slots CCW to bring the setting to
0.010–0.020" (.25–.51 mm) high.
5. Place cotter pin (15) through the slot, bend
over ends.
6. Continue reassembly per Sub-Section B,
Diaphragm Replacement, Step 16.
E. Trim Removal and Replacement:
1. Install body (1) horizontally in a vise with the
spring chamber (2) directed upwards, and the
body (1) held at the outlet end.
2. Use a box end wrench, or socket, with a lever
length of at least 24 inches (610 mm), and
place over the hex surfaces of the cylinder
(21). The wrench should be rapped with a
hammer to loosen.
3. Continue to unscrew cylinder (21) until
removed. The piston (24) and piston collar (23)
should come out by gravity with the cylinder
(21) removal.
CAUTION
4. If an Option 1000-17 piston spring (30)
is utilized, it also should be removed and
replaced at trim replacement.
5. Inspect inside surface of cylinder (21) at four
points:
a. Seat (21.2) ring. Check for erosion/
wear on seating surfaces. If wear is
excessive, consider utilizing Option
1000-15, stellited seat surface.
b. Seat (21.2). Check for wire drawing
between cylinder (21.1) and seat (21.2)
where pressed in. If wear exists here,
an Option 1000-14, integral seat, should
be utilized as a replacement.
Take precautions not to allow the piston (24) to fall
from within the cylinder (21); tip cylinder with hex
end down.

8IOM-1000HP-Differential
c. Place seat disc (25) into recessed end of
piston (24).
d. Place thread sealant on threaded portion
of seat disc screw (26), and manually
rotate piston (24) into seat disc screw (26)
(still fixed in vise) to secure seat disc (25).
Tighten seat disc screw (26) firmly. Do not
over-tighten to the point of embedding the
seat disc screw (26) into the seat disc
(25); the seat disc (25) should lay flat with
no rounded surface. A mechanical aid is
normally not required; hand tightening is
normally sufficient.
7. Insert piston assembly (24 - metal seat) (24,
25 and 26 composition (soft) seat) into end
of cylinder (21).
8. Place piston collar (23) over the end of piston
(24), ensuring that the spherical surface of
the piston (24) and the piston collar (23) bear
against each other.
9. Clean the body (1) cavity through the openings.
Clean the “jet area” just inside the body (1)
outlet end through which the piston (24)
projects. Clean all parts to be reused.
10. Use special care cleaning the flat mating
surfaces of the body (1) and cylinder (21)
shoulder, as this pressurized joint is metal-to-
metal with no gasket. (See NOTE next step.)
11. Lubricate the cylinder (21) threads lightly with
thread sealant. Insert the entire trim stack into
the body (1) opening and screw until tightly
seated. Using the hammer and wrench handle,
impact the cylinder (21) into the body (1).
NOTES: 1. Take special precaution to keep
piston collar from getting “cocked” at an angle
when inserted.
2. On 2" brass bodies (1) with brass trim, a TFE
body O-ring (43) is utilized to seal between the
body (1) and the cylinder (21) subassembly.
This O-ring is not indicated on drawings.
12. Inspect the body (1) outlet end to ensure that
the piston (24) is located nearly concentric to
the body (1) bore in the jet area with clearance.
Under no condition should the piston (24)
be touching the body (1). Use two pencils or
similar shafts to place in inlet and outlet ends
of regulator and alternately push on each end
c. Flow induced wear at expansion zone
where fluid turns to enter the piston (24)
center.
d. Where the piston (24) ribbed guides bear
(guide zone).
If wear is significant at any of these points,
both cylinder subassembly (21) and piston
subassembly (24 or 24, 25, and 26) should
be replaced. (Cashco does not recommend
attempting to replace the seat (21.2) by
pressing out and then repressing in. Cashco
also recommends that a cylinder (21) and
piston (24 or 24, 25 and 26) be replaced as
a set. Composition seat discs (25) may be
replaced individually.
6. If a composition (soft) seat trim design is
utilized, use the following sub-steps:
a. Tighten the “flats” of the seat disc screw
(26) within a vise. Firmly hand-grip the
piston (24) and turn CCW to loosen the
seat disc screw (26). If too tight, place a
screwdriver or similar rod within the piston
(24) port holes and rotate. Remove the
piston (24), and inspect for raised burrs
around the port holes if a device is used
to loosen; de-burr as required. NOTE: Do
not grip the piston (24) with a wrench.
b. Remove the seat disc (25) and clean the
recessed piston (24) area where the seat
disc (25) is placed. If the edges which form
the recess of the piston (24) are worn, also
replace piston (24) and seat disc screw
(26).

9IOM-1000HP-Differential
of the piston (24) to ensure free movement.
(Total movement is approximately 1/8"
(3mm).
13. Bench test unit for suitable operation and
seat leakage. NOTE: Regulators are not
1. Erratic operation; chattering.
Possible Causes Remedies
A. Oversized regulator; inadequate rangeability. A1. Check actual flow conditions, resize regulator for
minimum and maximum flow.
A2. Increase flow rate.
A3. Decrease regulator pressure drop; decrease inlet
pressure by placing a throttling orifice in inlet
piping union.
A4. Replace full orifice with reduced orifice; i.e. new
cylinder required.
B. Worn piston/cylinder; inadequate guiding. B. Replace trim.
C. Flow induced instability. C1. Get straight runs of piping (5 diameters upstream,
10 downstream) to and from regulator.
C2. Ensure outlet velocity is not excessive; use pipe
reducer close to regulator outlet.
C3. Add next higher range spring. Contact factory.
C4. If composition diaphragm, switch to metal
diaphragm.
D. Improper (oversized) jet. D. Replace existing piston with new piston with
proper jet.
E. Plugged trim. E. Remove trim and check for plugged holes in
piston, or debris in guide zone or jet zone.
F. Unstable loading pressure. F1. Stabilize loading pressure; i.e. pump, control
valve, etc.
F2. Air in loading piping. Vent spring chamber.
VII. TROUBLE SHOOTING GUIDE
SECTION VII
normally tight shutoff devices. Pressure must
build above setpoint for best shutoff.
14. Soap solution test around cylinder (21)-to-
body (1) connection for leakage. Test
pressure should be a minimum of 100 psig at
the inlet or actual service conditions if higher.

10 IOM-1000HP-Differential
2. Regulator differential pressure too low.
Possible Causes Remedies
A. Setpoint too low. A. Turn adjusting screw down (CW) to increase
setpoint.
B. Regulator undersized; outlet pressure B1. Confirm by opening bypass valve together with
(P2) droops below loading pressure regulator.
(PLoad). B2. Check actual flow conditions, resize regulator;
if regulator has inadequate capacity, replace with
larger unit.
C. Plugged inlet strainer. C. Remove strainer screen and clean; consider
leaving screen out.
D. Plugged trim. D. Remove trim and check for plugged holes in
piston, or debris in guide zone or jet zone.
E. Incorrect range spring (turning adjusting E. Replace range spring with proper higher range.
screw CW does not allow bringing pressure Contact factory.
level up to proper level).
F. Too much proportional band (droop); F1. Review P.B. (droop) expected. (See 2.B1 above.)
outlet pressure (P2) droops below loading F2. Diaphragm setting too low; check setting and
pressure (PLoad). raise as required.
F3. Consider composition diaphragm over metal.
F4. Improper jet; make sure jet matches actual fluid.
G. Restricted diaphragm movement. (Pressure G. Diaphragm setting too low; check and raise
plate hitting downstops.) as required.
3. Leakage through the body spacer vent hole, or mixing of fluids.
Possible Causes Remedies
A. Normal-life diaphragm failure. A. Replace diaphragm.
B. Abnormal short-life diaphragm failure. B1. Can be caused by excessive chattering. See No.
1. to remedy valve chatter.
B2. Can be caused by corrosive action. Consider
alternate diaphragm material.
B3. For composition diaphragms, ensure not subject-
ing to over-temperature conditions.
B4. Downstream (outlet) pressure buildup occurring
that overstresses diaphragms.
B5. Shutoff of valve inlet pressure while loading
pressure is still on.
C. Pusher plate gasket or O-Ring leaking. C. Replace gasket and O-ring.

11 IOM-1000HP-Differential
4. Excessive pressure downstream.
Possible Causes Remedies
A. Regulator not closing tightly. A1. Overly compressed range spring; i.e. approaching
solid height. Use next higher range spring.
A2. Inspect the seating. Clean and lap metal seat
surfaces; replace if lapping does not remedy. If
composition seats are depressed, nicked or
embedded with debris, replace seat disk.
A3. Diaphragm setting too high; check setting.
A4. Inlet pressure too high for orifice size; check
permissible inlet (P1) pressure level for a given
outlet. Change to reduced port if required.
A5. Leakage past pressed in seat ring; consider
integral seat.
A6. When diaphragm subassembly was put into place,
the rocker arm got between the stud collar and the
stud nut rather than on top of the stud collar.
B. Downstream block. B. Check system; isolate (block) flow at regulator
inlet, not outlet. Relocate regulator if necessary.
C. No pressure relief protection. C. Install safety relief valve, or rupture disc.
D. Restricted diaphragm movement. D1. Diaphragm setting too high; check and lower
as required.
D2. Ensure no moisture in spacer ring at temperatures
below freeze point. Ensure no dust or debris
entering vent opening. If rainwater or debris can
enter, reorient spring chamber. (Not possible on
-1+6.)
5. Sluggish operation.
Possible Causes Remedies
A. Plugged piston or jet zone. A. Remove trim and clean.
B. Fluid too viscous. B. Heat fluid.
C. Improper (undersized) jet. C. Replace existing piston with new piston for
viscous service; i.e. Opt-27.
6. Frequent resetting of setpoint.
Possible Causes Remedies
A. Overpressurization downstream resulting in: A1. Replace diaphragms. Correct potential source of
1. Bent metal diaphragm(s) downstream overpressure.
2. Sprung rocker arm A2. Check measurements of rocker arm. Replace if
3. Range spring overstressed/fatigued. necessary.
A3. Replace range spring; consider next higher range
spring.

12 IOM-1000HP-Differential
7. Not able to maintain setpoint.
Possible Causes Remedies
A. Diaphragm may be bent due to pressure A. Make sure to prevent system reversal.
reversal.
8. Excess leakage:
Possible Causes Remedies
A. Faulty seating surfaces. A1. Seat has been nicked by welding splatters.
A2. Composition seat is damaged.
A3. Composition seat driven into metal seat surface
due to overpressure.
B. Outlet pressure setting too low for inlet B. Refer to Technical Bulletin.
pressure.

13 IOM-1000HP-Differential
SECTION VIII
NEW REPLACEMENT UNIT:
Contact your local Cashco, Inc., Sales Represen-
tative with the Serial Number and Product code.
With this information they can provide a quotation
for a new unit including a complete description,
price and availability.
–7–
VIII. ORDERING INFORMATION
NEW REPLACEMENT UNIT vs PARTS "KIT" FOR FIELD REPAIR
To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped
on the metal name plate and attached to the unit. This information can also be found on the Bill of Material
("BOM"), a parts list that was provided when unit was originally shipped. (Serial Number typically 6 digits).
Product Code typical format as follows: (last digit is alpha character that reflects revision level for the product).
PARTS "KIT" for FIELD REPAIR:
Contact your local Cashco, Inc., Sales Represen-
tative with the Serial Number and Product code.
Identify the parts and the quantity required to repair
the unit from the "BOM" sheet that was provided
when unit was originally shipped.
NOTE: Those part numbers that have a quantity indicated
under "Spare Parts" in column "A” reflect minimum
parts required for inspection and rebuild, - "Soft
Goods Kit". Those in column “B” include minimum
trim replacement parts needed plus those "Soft
Goods" parts from column "A".
If the "BOM" is not available, refer to the cross-
sectional drawings included in this manual for part
identification and selection.
A Local Sales Representative will provide quotation
for appropriate Kit Number, Price and Availability.
CAUTION
Do not attempt to alter the original construction
of any unit without assistance and approval from
the factory. All purposed changes will require a
new name plate with appropriate ratings and new
product code to accommodate the recommended
part(s) changes.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to
modify or improve the designs or specifications of such product at any time without notice.
Cashco, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any
Cashco, Inc. product remains solely with the purchaser.

14 IOM-1000HP-Differential
MODEL 1000HP-1+6
DIFFERENTIAL PRESSURE REDUCING REGULATOR
ITEM NO. DESCRIPTION
REPAIR PARTS
KIT A KIT B
1. BODY & BODY ASSY
2. SPRING CHAMBER
(or Loading Chamber)
3. PRESSURE PLATE
4. SPRING BUTTON
6. ADJUSTING SCREW
7. ADJUSTING SCREW LOCK NUT ***
9. FLANGE NUT
10. STUD NUT
11. PRESSURE PLATE NUT ***
12. PUSHER PLATE GASKET ***
13. PUSHER PLATE STUD
14. ROCKER ARM
15. COTTER PIN **
16. STUD COLLAR
17. ROCKER ARM SHAFT
ITEM NO. DESCRIPTION
REPAIR PARTS
KIT A KIT B
19. DIAPHRAGM GASKET ***
20. DIAPHRAGM(S) ***
21. CYLINDER ASSEMBLY **
21.1 CYLINDER
21.2 VALVE SEAT
23. PISTON COLLAR **
24. PISTON **
25. SEAT DISC ***
26. SEAT DISC SCREW **
27. RANGE SPRING
28. NAME PLATE
29. SEAT CONE (-15 OPT)
31. CLOSING CAP (-1 OPT)
32. CLOSING CAP GASKET (-1 OPT) ***
34 BLEEDER VALVE ASSEMBLY
50 O-RING ***
Items Not
Shown
5 Pusher Plate
18 Body Plug/Drain Tap
30 Piston Spring
33 Spring Chamber Pipe Plug
36 Identification Plate
(Supplied upon request)
43 Body O-ring

15 IOM-1000HP-Differential
MODEL 1000HP-1+8
DIFFERENTIAL PRESSURE REDUCING REGULATOR
Items Not
Shown
5 Pusher Plate
18 Body Plug/Drain Tap
30 Piston Spring
33 Spring Chamber Pipe Plug
36 Identification Plate
(Supplied upon request)
43 Body O-ring
ITEM NO. DESCRIPTION REPAIR PARTS
KIT A KIT B
1. BODY & BODY ASSY
2. SPRING CHAMBER
(or Loading Chamber)
3. PRESSURE PLATE
4. SPRING BUTTON
6. ADJUSTING SCREW
7. ADJUSTING SCREW LOCK NUT ***
9. FLANGE NUT
10. STUD NUT
11. PRESSURE PLATE NUT ***
12. PUSHER PLATE GASKET ***
13. PUSHER PLATE STUD
14. ROCKER ARM
15. COTTER PIN **
16. STUD COLLAR
17. ROCKER ARM SHAFT
ITEM NO. DESCRIPTION REPAIR PARTS
KIT A KIT B
19. DIAPHRAGM GASKET ***
20. DIAPHRAGM(S) ***
21. CYLINDER ASSEMBLY **
21.1 CYLINDER
21.2 VALVE SEAT
23. PISTON COLLAR **
24. PISTON **
27. RANGE SPRING
28. NAME PLATE
29. SEAT CONE (-15 OPT)
31. CLOSING CAP (-1 OPT)
32. CLOSING CAP GASKET (-1 OPT) ***
34 BLEEDER VALVE ASSEMBLY
41. DIAPHRAGM SPACER
42. BODY SPACER
50 O-RING ***

16 IOM-1000HP-Differential
ATEX 94/9/EC: Explosive Atmospheres and Cashco Inc. Regulators
These valves satisfy the safety conditions according to EN 13463-1 and EN 13463-5 for equipment group IIG 2 c.
Caution: Because the actual maximum temperature depends not on the equipment itself, but upon the fluid temperature, a
single temperature class or temperature cannot be marked by the manufacturer.
Specific Precaution to Installer: Electrical grounding of valve must occur to minimize risk of effective electrical discharges.
Specific Precaution to Installer: Atmosphere vent holes should be plugged to further minimize the risk of explosion.
Specific Precaution to Maintenance: The Valve Body/ Housing must be regularly cleaned to prevent buildup of dust deposits.
Specific Precaution to Maintenance: Conduct periodic Continuity Check between Valve Body/ Housing and Tank to minimize
risk of electrical discharges.
Attention: When repairing or altering explosion-protected equipment, national regulations must be adhered to. For maintenance
and repairs involving parts, use only manufacturer's original parts.
ATEX requires that all components and equipment be evaluated. Cashco pressure regulators are considered components.
Based on the ATEX Directive, Cashco considers the location where the pressure regulators are installed to be classified
Equipment-group II, Category 3 because flammable gases would only be present for a short period of time in the event of a leak.
It is possible that the location could be classified Equipment-group II, Category 2 if a leak is likely to occur. Please note that the
system owner, not Cashco, is responsible for determining the classification of a particular installation.
Product Assessment
Cashco performed a conformity assessment and risk analysis of its pressure regulator and control valve models and their
common options, with respect to the Essential Health and Safety Requirements in Annex II of the ATEX directive. The details
of the assessment in terms of the individual Essential Health and Safety Requirements, are listed in Table 1. Table 2 lists all of
the models and options that were evaluated and along with their evaluation.
Models and options not listed in Table 2 should be assumed to not have been evaluated and therefore should not be selected
for use in a potentially explosive environment until they have been evaluated.
Standard default options for each listed model were evaluated even if they were not explicitly listed as a separate option in the
table. Not all options listed in the tables are available to all models listed in the tables. Individual TB’s must be referenced for
actual options.
When specifying a regulator that is to be used in a potentially explosive environment one must review the evaluations in Table 1
and 2 for the specific model and each and every option that is being specified, in order to determine the complete assessment
for the unit.
A summary of the models and options found to have an impact on ATEX assessment due to potential ignition sources or other
concerns from the ATEX Essential Health and Safety Requirements, are listed below.
1. The plastic knob used as standard on some models, (P1, P2, P3, P4, P5, P7, 3381, 4381, 1171, and 2171) is a
potential ignition source due to static electricity. To demonstrate otherwise, the knob must be tested to determine
if a transferred charge is below the acceptable values in IEC 60079-0 Section 26.14 (See items 25, 27, and 28 in
Appendix A). Until the plastic knob has been shown to be acceptable, then either the metal knob option, or a preset
outlet pressure option is required to eliminate this ignition source (See items 45 and 64 in Tables).
2. The pressure gauges offered as options on a few of the regulator models (DA’s, P1-7, D, 764, 521), use a plastic
polycarbonate window that is a potential ignition source due to static electricity. To demonstrate that the gauges are
not a potential source of ignition, the gauges would need to be tested to determine if a transferred charge is below
NOTICE
Only for Product Codes wherein hazard
category ATEX has been selected.

17 IOM-1000HP-Differential
indicating the gauge is compliant with the ATEX Directive (See items 26, 27, and 28 in Appendix A). Until compliance
is determined, regulators should not be ordered with pressure gauges for use in potentially explosive environments.
3. Tied diaphragm regulators with outlet ranges greater than 100 psig should be preset to minimize the risk that improper
operation might lead to an outboard leak and a potentially explosive atmosphere (See item 6 in Table 1).
4. Regulators must be ordered with the non-relieving option (instead of the self-relieving option) if the process gas they are
to be used with is hazardous (flammable, toxic, etc.). The self-relieving option vents process gas through the regulator
cap directly into the atmosphere while the non-relieving option does not. Using regulator with the self- relieving option
in a flammable gas system could create an explosive atmosphere in the vicinity of the regulator.
5. Regulators with customer supplied parts are to be assumed to not have been evaluated with regard to ATEX and thus
are not to be used in a potentially explosive environment unless a documented evaluation for the specific customer
supplied parts in question has been made. Refer to Table 1 for all models and options that have been evaluated.
Product Usage
A summary of ATEX related usage issues that were found in the assessment are listed below.
1. Pressure regulators and control valves must be grounded (earthed) to prevent static charge build-up due to the flowing
media. The regulator can be grounded through any mounting holes on the body with metal to metal contact or the
system piping can be grounded and electrical continuity verified through the body metal seal connections. Grounding
of the regulator should follow the same requirements for the piping system. Also see item 30 in Table 1.
2. The system designer and users must take precautions to prevent rapid system pressurization which may raise surface
temperatures of system components and tubing due to adiabatic compression of the system gas.
3. Heating systems installed by the user could possibly increase the surface temperature and must be evaluated by the
user for compliance with the ATEX Directive. User installation of heating systems applied to the regulator body or
system piping that affects the surface temperature of the pressure regulator is outside the scope of this declaration and
is the responsibility of the user.
4. The Joule-Thomson effect may cause process gases to rise in temperature as they expand going through a regulator.
This could raise the external surface temperature of the regulator body and downstream piping creating a potential
source of ignition. Whether the Joule-Thomson effect leads to heating or cooling of the process gas depends on
the process gas and the inlet and outlet pressures. The system designer is responsible for determining whether the
process gas temperature may rise under any operating conditions. If a process gas temperature rise is possible under
operating conditions, then the system designer must investigate whether the regulator body and downstream piping
may increase in temperature enough to create a potential source of ignition.
The process gas expansion is typically modeled as a constant enthalpy throttling process for determining the temperature change.
A Mollier diagram (Pressure – Enthalpy diagram with constant temperature, density, & entropy contours) or a Temperature –
Entropy diagram with constant enthalpy lines, for the process gas, can be used to determine the temperature change. Helium
and hydrogen are two gases that typically increase in temperature when expanding across a regulator. Other gases may
increase in temperature at sufficiently high pressures.
Product Declaration
If the above issues are addressed by selecting options that do not have potential sources of ignition, avoiding options that
have not been assessed, and by taking the proper usage issue precautions, then Cashco regulators can be considered to be a
mechanical device that does not have its own source of ignition and thus falls outside the scope of the ATEX directive.
Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
Fax. # [phone]
www.cashco.com
email: [email protected]
Printed in U.S.A. C-BPV-TB
Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
email: [email protected]
Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
email: [email protected]